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DENIM WASHING

PREPARED BY:-
-UTSAV SHAH(434043)
-JAYANT PATIL(434038)
DEPARTMENT:-
-TEXTILE PROCESSING

Faculty of Technology & engineering


The Maharaja Sayajirao University of baroda
INTRODUC-
INTRODUC-
TION
TION

REFERENCE
REFERENCE OBJECTS
OBJECTS

CONTENTS

TYPES
TYPES
MECHANI-
MECHANI- OF
OF
CAL
CAL WASH
WASH WASH
WASH

CHEMICAL
CHEMICAL
WASH
WASH
INTRODUCTION(9)
 Denim is a rugged cotton twill textile in which the weft
yarns passes under two or more warp yarns.
 In dyeing of denim only warp yarn is traditionally dyed with
the blue colour obtained from indigo dyes.
 It is the future of fabric because denim is used by all human
beings around the world.
Objectives Of Denim Washing(6)
Washing of denim is a most important finishing treatment in textile
industries. It has the largest effect on the physico-mechanical properties on
denim garment. Objectives:-
1. Faded or worn out effects could be introduced to the garment which creates
new fashion.
2. Softness could be increased by the addition of softener just at the last sage
of washing.
3. Removal of starch or size materials makes the garments soft hand feel.
4. Improving the quality of final product and also increase the aesthetic value
in the market.

“provides the garment an identity and exclusive appearance and helps in

creating a brand image”


Classification of denim washes(8)

TYPES
TYPES OF
OF
WASHES
WASHES

MECHANICAL
MECHANICAL CHEMICAL
CHEMICAL
WASHES
WASHES WASHES
WASHES

STONE
STONE SAND
SAND OZONE ENZYME DENIM
OZONE ENZYME DENIM
WASH
WASH BLASTING
BLASTING FADDING
FADDING ACID
ACID WASH
WASH
WASH
WASH BLEACH
BLEACH
1. Stone Wash
 This method is most common and it is used to give “old look” on the denim
fabric. In this process pumice stone are most important component.
 Selection of stone
 Large, hard stones last longer and may
be suited for heavy weight fabrics
only.
 Smaller, softer stones would be used
for light weight fabrics and more
delicate items.
 Stone weight/ fabric weight= 0.5 to 3/1
PROCESS FLOW CHART OF STONE WASH
DESIZING
DESIZING
+ENZYME
+ENZYME OR
OR
OXIDATIVE 30-60
30-60 MINITUES
MINITUES
GARMENT
GARMENT OXIDATIVE
DESIZING
DESIZING

RINSING WASHING
WASHING
DESIZING
DESIZING RINSING
LOADING
LOADING

STONES
STONES
REMOVING
REMOVING
STONES RINSING
RINSING
STONES FROM
FROM
THE GARMENT
THE GARMENT

DRYEING
DRYEING UNLOADING
UNLOADING EXTRACTING
EXTRACTING SOFTNING
SOFTNING
LIMITATIONS
 Outcome of a load of jeans is never uniform.

 Damage to wash machineries and garment due to stone to


machine abrasion.
 Increase in labour to remove stone particles from finished
garments.
 Water pollution during disposal of used liquor.
2. SAND BLASTING (7)
 This process is used to produce localized abrasion effect.
Usually, aluminum oxide granules are blasted onto the
surface at a very high speed.
PROCESS FLOW CHART OF SAND BLASTING

RUBBER
RUBBER BOARD
BOARD
GARMENT SELECT
SELECT PLACING
PLACING
GARMENT MARKING 
COLLECT PRESSURE
PRESSURE INSIDE
INSIDE MARKING 
COLLECT
AND
AND ANGLE
ANGLE GARMENT 
GARMENT 

GARMENTS
GARMENTS
ARE
ARE TAKEN
TAKEN
TO
TO CHAMBER 
CHAMBER 

SAND
SAND BLOWING
BLOWING
WET
WET WASH 
WASH     REPEAT 
REPEAT  CONTINUE FROM
FROM GUN
GUN ON
ON
CONTINUE
GARMENTS 
GARMENTS 
Advantages
 It is purely mechanical process, not using any chemicals.

 It is a water free process therefore no drying required.

 Variety of distressed or abraded looks possible.

 Any number of designs could be created by special


techniques.
3.OZONE FADING (4)
Today, many companies are turning to this new technology, the
technology is based on a natural process of oxygen enrichment.
Denim garment can also be faded by using ozone gas.
Advantages

 Colour removal is possible without lossing strength.

 This method is very simple.

 No harmful effect on environment.

 Gives very good results on denim compare to other processes


of washing.
4. Enzyme wash(3)
 Application of organic enzymes. Enzyme is one kind of protein
that is obtained from fermentation method from naturally existing
bacteria & fungi. Also known as “bio-stone washing”.
PROCESS FLOW CHART OF ENZYME WASH

ADJUSTING
ADJUSTING PHPH
4.5-5.5
4.5-5.5 DIFF ..
DIFF
GARMENT TEMP.
TEMP. FOR
FOR DIFF.
DIFF.
ENZYME
ENZYME

DESIZING RINSE
RINSE ADITION OF
LOADING (TWO
(TWO TIME)
TIME) ENZYME

(TEMP.60OOC
FOR 20 30-60
TUMBLING
MINUTES) MINUTES

RINSE
DRYING EXTRACTING SOFTNING
(TWO TIME)
Merits
Demerits
Approaches “clean Post treatments are required.
chemistry” so no adverse Garment load size of the
effect on environment. machine is limited.
Gives good result compare to Sometimes it could leave
other washing processes. marks of back staining.
Reduces the % of damage
caused by the rough effect of
stones .
The effect of treatment is
long lasting & gives more
reproducible results.
Replacement of washing by
pumice stones.
5. Acid wash(2)

 It is also a one type of stone wash. Generally this wash is performed in two
steps: 1.Pumice stones are pre soaked in a solution of NaOCl or KMnO4.
2.Tumbling the garment in stones treated.
PROCESS FLOW CHART OF ACID WASH WASH

(room temp.
GARMENTS
for 15
LOADING
IN minutes)
MACHINE

SOAKING
EXTRACTING OF PUMICE
DE-SIZE THE DRYING STONE
GARMENTS

(temp.6000C DAMP PUMICE


(room temp. STONE
for 20 for 20 minutes)
minutes)

EXTRACTING NEUTRALIZATI
THE SOFTENING ON THE
DRYING
GARMENTS GARMENTS
Limitations Remedies

Acid washed, indigo dyed denim Acid washing jeans avoided


some of problems of stone
has a tendency to yellow after wet wash, but came with added
processing. dangers, expenses, and
pollution.

The major cause is residual Manganese is effectively


removed during laundering with
maganese due to incomplete
addition of EDTA as chelating
neutralization, washing or rinsing. agent.
6. Denim bleach(5)
This process is quite similar to the acid wash, but
in this process washing is done with or without stone
addition.
PROCESS FLOW CHART DENIM BLEACH OF WASH

(temp.40 to
(temp.60 OOC 60OOC for 45
Garment for 20 (15 minutes) minutes)
minutes)

Treat with Bleach with


Loading Desize cold water KMnO4

(temp.50 OOC
(With Or Optical
for
Without Stone) brightening
20minutes)

(temp.4000C for
15minutes) Softening
Limitations

Sometimes problem of yellowing occurs,

Causes corrosion of machine parts,

Source of environmental pollution,

Required anti-chloro treatment.


3E bleaching concept(8)
This technology is based on a (a redox enzyme using mol.
Oxygen as electron acceptor) and mediator.
A mediator is necessary and a chemical mediator is
employed between enzyme and indigo.
Intensive research is underway for the development of
Sodium hypochlorite bleaching alternative eg. Glucose
bleaching, bleaching with sulphinic acid derivatives, and
recently with laccase (one type of enzyme).
Advantages Disadvantages
This process is based on Expensive compared to
enzyme so no risk of traditional processes.
environment pollution.
The product is so specialised Heavy faded look is difficult to
on indigo that it does not achieve.
attack any other dye.
• References:-
1. D. P. Chattopadhyay and R.D. Pachauri, "Preparation of synthetic stones
for denim washing & analysis of wash effects", Textiles and light industrial
science & Tech., volume 1(2), pages.1 to 4, 2012.
2. U. N. Haq and M.R. Khan, "Technology of acid wash on woven denim
apparel with damp pumice stone", International journal of science,
environment & Tech., vol. 3, pages. 2090 to 2095, 2014.
3. I. H. Mondal, M. R. Khan and F. A. Ahmed, "Physical-Mechanical
properties of finished denim garment by stone enzymatic treatment",
Journal of textile and apparel, Tech. & management, vol.10(1), pages.1 to
4, 2016
4. Anurag Singh, "Denim washing", Technology & Business, volume.1(3),
pages.1 to 8, 2014.

5. "Manufacture of denim", Small industries service institute, Gov. of India


(ministry of SSI), company. volume.1(1), pages.67 to69, 2003.

6. "Garment washing techniques for cotton apparel" Cotton incorporated


research center, A technical bulletin, volume. 1(1), pages. 2 to 6, 1992.

7. C. H. Chaterjee, "Different methods for denim washing " Denim 2006


& Indo-us summit, Ahmadabad, volume. 1(1), pages.1 to 12.
8. Archroma global denim center, "Denim book/from cotton to fashion",
Advanced denim, volume.1(1), pages. 38 to 55, 2004.
THE END

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